Senior Director - Process Safety

EMIRATES GLOBAL ALUMINIUM (EGA); Abu Dhabi; On-site; AED 600,000 - 1,200,000; Full time

Job summary

Emirates Global Aluminium (EGA) is seeking a Senior Leader for Major Hazard Governance to establish and maintain an enterprise-wide risk management framework for major hazards, including molten metal handling, high-voltage systems, gas systems, and pressure systems.

You will lead SIF/HiPo frameworks, monitor barrier health, oversee independent verification programs, and provide board-level visibility of risk exposure.

Qualifications

• Bachelor's degree in engineering and minimum 15 years of experience in high-hazard industrial operations.
• Expertise in HAZOP, LOPA, Bowtie Risk Analysis, CCM, Major Accident Prevention, regulatory engagement, and board committee reporting.
• Experience with digital technologies, data analytics, and Process Safety systems.

Responsibilities

• Establish and maintain an enterprise-wide Major Hazard Risk Management Framework.
• Define, implement, and oversee Critical Controls for major hazard exposures including molten metal handling and transfer operations, pipeline integrity and high-voltage electrical systems, gas systems, pressure systems and stored energy hazards, and confined space entry.
• Ensure governance and control frameworks align with ICMM, CCPS, OSHA, PSM principles, and SIF prevention.
• Lead SIF and HiPo Event Frameworks with clear definitions, escalation thresholds, and governance reviews with the Executive Committee.
• Monitor barrier health and Critical Control effectiveness, identify degradation and overdue verifications, and tighten risk controls.
• Provide independent verification for Life-Saving Rules and Critical Controls with field validation and evidence-based assurance.
• Deliver board-level visibility of major hazard exposure and Critical Control performance via dashboards.
• Authorize stop or suspension of high-risk operations and enforce MOC outcomes and verification standards.
• Drive leadership accountability and continuous improvement in process safety culture and governance.
• Provide quarterly board reporting on Tier 1/2 Process Safety Events, Barrier Health Index, and risk exposure heat map.

Skills

HAZOP

LOPA

Bowtie Risk Analysis

Critical Control Management

Major Accident Prevention

Regulatory engagement

Board reporting

Digital technologies

Data analytics

Process Safety systems

Education

Bachelor's Degree in Engineering (Chemical, Mechanical, Electrical, Process Engineering, or a related discipline)

Job description

Major Hazard Governance

Establish and maintain an enterprise-wide Major Hazard Risk Management Framework.

Define, implement, and oversee Critical Controls for major hazard exposures including molten metal handling and transfer operations, pipeline integrity and high-voltage electrical systems, gas systems (e.g., natural gas, hydrogen, and compressed gases), pressure systems and stored energy hazards, and confined space entry and other high-risk activities.

Ensure governance and control frameworks are aligned with recognized international standards and industry best practices, including International Council on Mining and Metals (ICMM), Critical Control Management Guidance Center for Chemical Process Safety (CCPS), Risk-Based Process Safety Framework, Occupational Safety and Health Administration (OSHA), Process Safety Management (PSM) Principles, and Fatality & Serious Injury Prevention (SIF).

SIF Focus

Lead the strategic shift from traditional lagging safety metrics (T-RIFR, LTI-FR) toward Serious Injury and Fatality (SIF) prevention, ensuring the organization prioritizes catastrophic risk exposure and Major Accident Event (MAE) prevention.

HiPo Event Framework

• Establish and govern a robust SIF and High Potential (HiPo) Event Framework, including clear definitions, classification criteria, and escalation thresholds.
• Monitor and report barrier health and Critical Control effectiveness by detecting control degradation, monitoring overdue verification activities, and identifying weak signals of operational drift.
• Ensure all High Potential events (Critical Control failures and recurring systemic weaknesses) are reviewed with the Executive Committee, including credible worst-case outcomes and immediate corrective actions.
• Implement and oversee an independent verification program for Life-Saving Rules and Critical Controls, ensuring high-risk controls are tested against defined performance standards and verified through field validation and evidence-based assurance.
• Track through governance dashboards and escalate when non-compliant or ineffective.
• Ensure leadership accountability through SIF performance reviews and barrier assurance reporting.
• Provide board-level visibility of major hazard exposure and Critical Control performance.

Engineering & Asset Integrity

Provide governance and oversight of engineering systems that protect against major hazards, including mechanical integrity programs, electrical integrity, arc flash risk controls, and management of change (MOC) governance.

Oversee safe design reviews for new smelter technologies and modifications, ensuring Process Safety requirements are embedded into all capital projects, expansions, and major upgrades from concept through commissioning and operational handover.

Automation & AI in Process Safety

Lead the integration of advanced technologies to strengthen Process Safety performance and reduce catastrophic risk exposure.

• Integrate AI-based predictive analytics for early anomaly detection and emerging risk trends.
• Implement real-time monitoring of critical parameters such as temperature, pressure, and gas concentrations.
• Deploy smart sensors for molten metal transport systems and other high-risk equipment.
• Develop digital barrier management and Critical Control verification platforms.
• Automate shutdown and interlock systems to eliminate or minimize human exposure.

Board Reporting & Risk Transparency

Provide quarterly board-level reporting on key Process Safety and Major Hazard indicators, including Tier 1 and Tier 2 Process Safety Events, Critical Control Effectiveness Rate, Barrier Health Index, HiPo trends, mechanical integrity backlog, and risk exposure heat map.

Ensure the board has timely visibility of catastrophic risk exposure, emerging threats, the effectiveness of mitigation measures, and Critical Control performance.

Decision Making Authority

• Authorized to stop or suspend high-risk operations, including molten metal transfer, high-voltage electrical work, gas system activities, confined space entry, and major lifting operations.
• Approve and enforce Critical Control Performance Standards, including verification frequencies, assurance methodologies, and minimum compliance thresholds.
• Require immediate corrective actions and establish risk-based deadlines when major hazard exposure is elevated or Critical Controls are failing.
• Approve or reject MOC outcomes for modifications affecting processes, equipment, technology, procedures, and operating conditions.
• Challenge operational decisions and require revalidation of risk assessments where hazard studies are incomplete, outdated, or poorly scoped.
• Identify residual risk that is not within acceptable limits.

Decision Making

Identify critical factors affecting major hazard risks and operational safety, evaluate alternatives, and establish priorities based on risk exposure.

Anticipate potential outcomes and assess operational consequences, making informed decisions under conditions of uncertainty and elevated risk.

Apply sound engineering judgment, quantitative analysis, and risk-based decision-making principles to protect people, assets, environment, and business continuity.

Qualifications & Experience

Bachelor's Degree in Engineering (Chemical, Mechanical, Electrical, Process Engineering, or a related discipline).

Minimum 15 years of experience in high-hazard industrial operations.

• Demonstrated expertise in HAZOP, LOPA, Bowtie Risk Analysis, Critical Control Management (CCM), Major Accident Prevention, regulatory engagement, and board committee reporting.
• Experience with digital technologies, data analytics, and Process Safety systems.

Leadership Expectations

• Demonstrates independence and authority to elevate catastrophic risk concerns to executive management and the board.
• Exhibits judgment to stop unsafe, high-risk operations when Critical Controls are ineffective or degraded.
• Applies systems-thinking to identify root causes, systemic weaknesses, and cross-functional risk interactions.
• Influences senior leadership and operational teams to strengthen Process Safety culture, governance, accountability, and continuous improvement.
• Promotes a proactive approach to catastrophic risk prevention through visible leadership and effective decision-making.

Key Performance Indicators (Board-Level)

• Zero Tier 1 catastrophic Process Safety events.
• ≥95% Critical Control Verification Effectiveness.
• 100% Management of Change (MOC) compliance for all major risk changes.
• Continuous reduction in Serious Injury & Fatality (SIF) potential and High Potential (HiPo) events.
• 100% closure of high-risk corrective actions within agreed target timeframes.

Why This Role is Critical in the Aluminium Industry

Ensures effective management of major hazards associated with aluminium smelting operations, including molten metal handling at temperatures exceeding 700°C, high-amperage electrical systems, combustible dust hazards, and heavy lifting and crane operations.

Prevents catastrophic incidents such as multi-fatality events, major fires and explosions, significant asset damage, business interruption, and reputational loss.

Drives the organization's transition from reactive injury management to proactive catastrophic risk prevention through robust Major Hazard Governance, Critical Control Assurance, risk-based decision-making, and executive-level visibility of Process Safety performance.